Start-Up, Operation, and Maintenance Instructions

Transcription

1 Start-Up, Operation, and Maintenance Instructions Centrifugal liquid chillers are designed to provide safe and reliable service when operated within design specifications. When operating this equipment, use good judgment and safety precautions to avoid damage to equipment and property or injury to personnel. Be sure you understand and follow the procedures and safety precautions contained in the chiller instructions as well as those listed in this guide. DO NOT VENT refrigerant relief valves within a building. Outlet from rupture disc or relief valve must be vented outdoors in accordance with the latest edition of ANSI/ASHRAE 15 (American National Standards Institute/American Society of Heating, Refrigeration, and Air Conditioning Engineers). The accumulation of refrigerant in an enclosed space can displace oxygen and cause asphyxiation. PROVIDE adequate ventilation in accordance with ANSI/ASHRAE 15, especially for enclosed and low overhead spaces. Inhalation of high concentrations of vapor is harmful and may cause heart irregularities, unconsciousness, or death. Misuse can be fatal. Vapor is heavier than air and reduces the amount of oxygen available for breathing. Product causes eye and skin irritation. Decomposition products are hazardous. DO NOT USE OXYGEN to purge lines or to pressurize a chiller for any purpose. Oxygen gas reacts violently with oil, grease, and other common substances. NEVER EXCEED specified test pressures, VERIFY the allowable test pressure by checking the instruction literature and the design pressures on the equipment nameplate. DO NOT USE air for leak testing. Use only refrigerant or dry nitrogen. DO NOT VALVE OFF any safety device. BE SURE that all pressure relief devices are properly installed and functioning before operating any chiller. DO NOT WELD OR FLAMECUT any refrigerant line or vessel until all refrigerant (liquid and vapor) has been removed from chiller. Traces of vapor should be displaced with dry air or nitrogen and the work area should be well ventilated. Refrigerant in contact with an open flame produces toxic gases. DO NOT USE eyebolts or eyebolt holes to rig chiller sections or the entire assembly. DO NOT work on high-voltage equipment unless you are a qualified electrician. DO NOT WORK ON electrical components, including control panels, switches, starters, or oil heater until you are sure ALL POWER IS OFF and no residual voltage can leak from capacitors or solidstate components. LOCK OPENAND TAG electrical circuits during servicing. IF WORK IS INTERRUPTED, confirm that all circuits are deenergized before resuming work. AVOID SPILLING liquid refrigerant on skin or getting it into the eyes. USE SAFETY GOGGLES. Wash any spills from the skin with soap and water. If liquid refrigerant enters the eyes, IMME- DIATELY FLUSH EYES with water and consult a physician. 19XR Hermetic Centrifugal Liquid Chillers 50/60 Hz With HFC-134a SAFETY CONSIDERATIONS NEVER APPLY an open flame or live steam to a refrigerant cylinder. Dangerous over pressure can result. When it is necessary to heat refrigerant, use only warm (110 F [43 C]) water. DO NOT REUSE disposable (nonreturnable) cylinders or attempt to refill them. It is DANGEROUS AND ILLEGAL. When cylinder is emptied, evacuate remaining gas pressure, loosen the collar and unscrew and discard the valve stem. DO NOT INCINERATE. CHECK THE REFRIGERANT TYPE before adding refrigerant to the chiller. The introduction of the wrong refrigerant can cause damage or malfunction to this chiller. Operation of this equipment with refrigerants other than those cited herein should comply with ANSI/ASHRAE-15 (latest edition). Contact Carrier for further information on use of this chiller with other refrigerants. DO NOTATTEMPT TO REMOVE fittings, covers, etc., while chiller is under pressure or while chiller is running. Be sure pressure is at 0 psig (0 kpa) before breaking any refrigerant connection. CAREFULLY INSPECT all relief devices, rupture discs, and other relief devices AT LEAST ONCE A YEAR. If chiller operates in a corrosive atmosphere, inspect the devices at more frequent intervals. DO NOT ATTEMPT TO REPAIR OR RECONDITION any relief device when corrosion or build-up of foreign material (rust, dirt, scale, etc.) is found within the valve body or mechanism. Replace the device. DO NOT install relief devices in series or backwards. USE CARE when working near or in line with a compressed spring. Sudden release of the spring can cause it and objects in its path to act as projectiles. DO NOT STEP on refrigerant lines. Broken lines can whip about and release refrigerant, causing personal injury. DO NOT climb over a chiller. Use platform, catwalk, or staging. Follow safe practices when using ladders. USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift or move inspection covers or other heavy components. Even if components are light, use mechanical equipment when there is a risk of slipping or losing your balance. BE AWARE that certain automatic start arrangements CAN EN- GAGE THE STARTER, TOWER FAN, OR PUMPS. Open the disconnect ahead of the starter, tower fans, or pumps. USE only repair or replacement parts that meet the code requirements of the original equipment. DO NOT VENT OR DRAIN waterboxes containing industrial brines, liquid, gases, or semisolids without the permission of your process control group. DO NOT LOOSEN waterbox cover bolts until the waterbox has been completely drained. DOUBLE-CHECK that coupling nut wrenches, dial indicators, or other items have been removed before rotating any shafts. DO NOT LOOSEN a packing gland nut before checking that the nut has a positive thread engagement. PERIODICALLY INSPECT all valves, fittings, and piping for corrosion, rust, leaks, or damage. PROVIDE A DRAIN connection in the vent line near each pressure relief device to prevent a build-up of condensate or rain water. Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Book 2 PC 211 Catalog No Printed in U.S.A. Form 19XR-1SS Pg Replaces: New Tab 5a

2 Page SAFETY CONSIDERATIONS...1 INTRODUCTION...4 ABBREVIATIONS AND EXPLANATIONS...4 CHILLER FAMILIARIZATION Chiller Information Plate...5 System Components...5 Cooler...5 Condenser...5 Motor-Compressor...5 Control Center...5 Factory-Mounted Starter (Optional)...7 Storage Vessel (Optional)...7 REFRIGERATION CYCLE...7 MOTOR/OIL REFRIGERATION COOLING CYCLE...7,8 LUBRICATION CYCLE...8 Summary...8 Details...8 Oil Reclaim System...8 PRIMARY OIL RECOVERY MODE SECONDARY OIL RECOVERY METHOD STARTING EQUIPMENT Unit-Mounted Solid-State Starter (Optional)...9 Unit-Mounted Wye-Delta Starter (Optional)...10 CONTROLS Definitions...10 ANALOG SIGNAL DIGITAL SIGNAL VOLATILE MEMORY General...10 PIC System Components...10 PROCESSOR MODULE (PSIO) STARTER MANAGEMENT MODULE (SMM) LOCAL INTERFACE DEVICE (LID) 6-PACK RELAY BOARD 8-INPUT MODULES OIL HEATER CONTACTOR (1C) OIL PUMP CONTACTOR (2C) HOT GAS BYPASS CONTACTOR RELAY (3C) (Optional) CONTROL TRANSFORMERS (T1, T2, T4) OIL DIFFERENTIAL PRESSURE/POWER SUPPLY CONTROL AND OIL HEATER VOLTAGE SELECTOR (S1) LID Operation and Menus...13 GENERAL ALARMS AND ALERTS LID DEFAULT SCREEN MENU ITEMS MENU STRUCTURE TO VIEW POINT STATUS OVERRIDE OPERATIONS TIME SCHEDULE OPERATION TO VIEW AND CHANGE SET POINTS SERVICE OPERATION PIC System Functions...26 CAPACITY CONTROL ENTERING CHILLED WATER CONTROL DEADBAND PROPORTIONAL BANDS AND GAIN DEMAND LIMITING CHILLER TIMERS OCCUPANCY SCHEDULE Safety Controls...26 Shunt Trip (Option) Default Screen Freeze...28 Ramp Loading Control...28 CONTENTS 2 Page Capacity Override...28 High Discharge Temperature Control...29 Oil Sump Temperature Control...29 Oil Cooler...29 Remote Start/Stop Controls...29 Spare Safety Inputs...29 Spare Safety Alarm Contacts Condenser Pump Control...29 Condenser Freeze Prevention...29 Tower Fan Relay...29 Auto. Restart After Power Failure...30 Water/Brine Reset...30 RESET TYPE 1: REQUIRES AN OPTIONAL 8-INPUT MODULE RESET TYUPE 2: REQUIRES AN OPTIONAL 8-INPUT MODULE RESET TYPE 3 Demand Limit Control Option (Requires Optional 8-Input Module)...30 Surge Prevention Algorithm...30 Surge Protection...31 Lead/Lag Control...31 COMMON POINT SENSOR INSTALLATION CHILLER COMMUNICATION WIRING LEAD/LAG OPERATION FAULTED CHILLER OPERATION LOAD BALANCING AUTO RESTART AFTER POWER FAILURE Ice Build Control...33 ICE BUILD INITIATION START-UP/RECYCLE OPERATION TEMPERATURE CONTROL DURING ICE BUILD TERMINATION OF ICE BUILD RETURN TO NON-ICE BUILD OPERATIONS Attach to Network Device Control...34 ATTACHING TO OTHER CCN MODULES Service Operation...35 TO LOG ON TO LOG OFF HOLIDAY SCHEDULING START-UP/SHUTDOWN/RECYCLE SEQUENCE...36,37 Local Start-Up...36 Shutdown Sequence...36 Automatic Soft Stop Amps Threshold...37 Chilled Water Recycle Mode...37 Safety Shutdown...37 BEFORE INITIAL START-UP Job Data Required...37 Equipment Required...37 Using the Optional Storage Tank and Pumpout System...38 Remove Shipping Packaging...38 Open Oil Circuit Valves...38 Tighten All Gasketed Joints and Guide Vane Shaft Packing...38 Check Chiller Tightness...38 Refrigerant Tracer...38 Leak Test Chiller...38 Standing Vacuum Test...41 Chiller Dehydration...41 Inspect Water Piping...43 Check Optional Pumpout Compressor Water Piping...43 Check Relief Devices...43 Inspect Wiring...43 Carrier Comfort Network Interface...44

3 Page Check Starter...44 MECHANICAL STARTER BENSHAW, INC. SOLID-STATE STARTER Oil Charge...44 Power Up the Controls and Check the Oil Heater...44 SOFTWARE VERSION Set Up Chiller Control Configuration...45 Input the Design Set Points...45 Input the Local Occupied Schedule (OCCPC01S)...45 Input Service Configurations...45 PASSWORD INPUT TIME AND DATE CHANGE LID CONFIGURATION IF NECESSARY MODIFY CONTROLLER IDENTIFICATION IF NECESSARY INPUT EQUIPMENT SERVICE PARAMETERS IF NECESSARY MODIFY EQUIPMENT CONFIGURATION IF NECESSARY CHECK VOLTAGE SUPPLY PERFORM AN AUTOMATED CONTROL TEST Check Optional Pumpout System Controls and Compressor...47 High Altitude Locations...47 Charge Refrigerant Into Chiller XR CHILLER EQUALIZATION WITHOUT PUMPOUT UNIT 19XR CHILLER EQUALIZATION WITH PUMPOUT UNIT TRIMMING REFRIGERANT CHARGE INITIAL START-UP Preparation...48 Manual Operation of the Guide Vanes...49 Dry Run to Test Start-Up Sequence...49 Check Rotation...49 IF ROTATION IS PROPER IF THE MOTOR ROTATION IS NOT CLOCKWISE Check Oil Pressure and Compressor Stop...49 Calibrate Motor Current Demand Setting...49 To Prevent Accidental Start-Up...49 Check Chiller Operating Condition...50 Instruct the Customer Operator...50 COOLER-CONDENSER OPTIONAL PUMPOUT STORAGE TANK AND PUMPOUT SYSTEM MOTOR COMPRESSOR ASSEMBLY MOTOR COMPRESSOR LUBRICATION SYSTEM CONTROL SYSTEM AUXILIARY EQUIPMENT DESCRIBE CHILLER CYCLES REVIEW MAINTENANCE SAFETY DEVICES AND PROCEDURES CHECK OPERATOR KNOWLEDGE REVIEW THE START-UP, OPERATION, AND MAINTENANCE MANUAL OPERATING INSTRUCTIONS...50,51 Operator Duties...50 Prepare the Chiller for Start-Up...50 To Start the Chiller...50 Check the Running System...50 To Stop the Chiller...50 After Limited Shutdown...51 CONTENTS (cont) Page Extended Shutdown...51 After Extended Shutdown...51 Cold Weather Operation...51 Manual Guide Vane Operation...51 Refrigeration Log...51 PUMPOUT AND REFRIGERANT TRANSFER PROCEDURES Preparation...51 Operating the Optional Pumpout Unit...51 TO READ REFRIGERANT PRESSURES Chillers with Storage Tanks...53 TRANSFER REFRIGERANT FROM PUMPOUT STORAGE TANK TO CHILLER TRANSFER THE REFRIGERANT FROM CHILLER TO PUMPOUT STORAGE TANK Chillers with Isolation Valves...54 TRANSFER ALL REFRIGERANT TO CHILLER CONDENSER VESSEL TRANSFER ALL REFRIGERANT TO CHILLER COOLER VESSEL RETURN REFRIGERANT TO NORMAL OPERATING CONDITIONS GENERAL MAINTENANCE...55,56 Refrigerant Properties...55 Adding Refrigerant...55 Removing Refrigerant...55 Adjusting the Refrigerant Charge...55 Refrigerant Leak Testing...55 Leak Rate...55 Test After Service, Repair, or Major Leak...55 REFRIGERANT TRACER TO PRESSURIZE WITH DRY NITROGEN Repair the Leak, Retest, and Apply Standing Vacuum Test...55 Checking Guide Vane Linkage...55 Trim Refrigerant Charge...56 WEEKLY MAINTENANCE...56 Check the Lubrication System...56 SCHEDULED MAINTENANCE Service Ontime...56 Inspect the Control Center...56 Check Safety and Operating Controls Monthly...56 Changing Oil Filter...56 Oil Specification...57 Oil Changes...57 TO CHANGE THE OIL Refrigerant Filter...57 Oil Reclaim Filter...57 Inspect Refrigerant Float System...57 Inspect Relief Valves and Piping...57 Compressor Bearing and Gear Maintenance...57 Inspect the Heat Exchanger Tubes...58 COOLER CONDENSER Water Leaks...58 Water Treatment...58 Inspect the Starting Equipment...58 Check Pressure Transducers...58 Optional Pumpout System Maintenance...58 OPTIONAL PUMPOUT COMPRESSOR OIL CHARGE OPTIONAL PUMPOUT SAFETY CONTROL SETTINGS Ordering Replacement Chiller Parts

4 Page TROUBLESHOOTING GUIDE Overview...59 Checking the Display Messages...59 Checking Temperature Sensors...59 RESISTANCE CHECK VOLTAGE DROP CHECK SENSOR ACCURACY DUAL TEMPERATURE SENSORS Checking Pressure Transducers...60 COOLER AND CONDENSER PRESSURE CALIBRATION OIL DIFFERENTIAL PRESSURE/POWER SUPPLY MODULE CALIBRATION TRANSDUCER REPLACEMENT Control Algorithms Checkout Procedure...61 Control Test...61 Control Modules...71 RED LED GREEN LEDs CONTENTS (cont) Page Notes on Module Operation...71 Processor Module (PSIO)...72 INPUTS OUTPUTS Starter Management Module (SMM)...72 INPUTS OUTPUTS Options Modules (8-Input)...72 Replacing Defective Processor Modules...73 INSTALLATION Solid-State Starters...74 TESTING SILICON CONTROL RECTIFIERS IN BENSHAW, INC. SOLID-STATE STARTERS Physical Data...77 INDEX...90,91 INITIAL START-UP CHECKLIST FOR 19XR HERMETIC CENTRIFUGAL LIQUID CHILLER...CL-1 to CL-12 INTRODUCTION Prior to initial start-up of the 19XR unit, those involved in the start-up, operation, and maintenance should be thoroughly familiar with these instructions and other necessary job data. This book is outlined so that you may become familiar with the control system before performing start-up procedures. Procedures in this manual are arranged in the sequence required for proper chiller start-up and operation. This unit uses a microprocessor control system. Do not short or jumper between terminations on circuit boards or modules; control or board failure may result. Be aware of electrostatic discharge (static electricity) when handling or making contact with circuit boards or module connections. Always touch a chassis (grounded) part to dissipate body electrostatic charge before working inside control center. Use extreme care when handling tools near boards and when connecting or disconnecting terminal plugs. Circuit boards can easily be damaged. Always hold boards by the edges and avoid touching components and connections. This equipment uses, and can radiate, radio frequency energy. If not installed and used in accordance with the instruction manual, it may cause interference to radio communications. It has been tested and found to comply with the limits for a Class A computing device pursuant to Subpart J of Part 15 of FCC Rules, which are designed to provide reasonable protection against such interference when operated in a commercial environment. Operation of this equipment in a residential area is likely to cause interference, in which case the user, at his own expense, will be required to take whatever measures may be required to correct the interference. Always store and transport replacement or defective boards in anti-static shipping bag. ABBREVIATIONS AND EXPLANATIONS Frequently used abbreviations in this manual include: CCN Carrier Comfort Network CCW Counterclockwise CW Clockwise ECW Entering Chilled Water ECDW Entering Condenser Water EMS Energy Management System HGBP Hot Gas Bypass I/O Input/Output LCD Liquid Crystal Display LCDW Leaving Condenser Water LCW Leaving Chilled Water LED Light-Emitting Diode LID Local Interface Device OLTA Overload Trip Amps PIC Product Integrated Control PSIO Processor Sensor Input/Output Module RLA Rated Load Amps SCR Silicon Control Rectifier SI International System of Units SMM Starter Management Module TXV Thermostatic Expansion Valve Words printed in all capital letters or in italics may be viewed on the LID. The PSIO software version number of your 19XR unit will be located on the PSIO module. 4

5 CHILLER FAMILIARIZATION (Fig. 1 and 2) Chiller Information Plate The information plate is located on the right side of the chiller control center panel. System Components The components include the cooler and condenser heat exchangers in separate vessels, motor-compressor, lubrication package, control center, and motor starter. All connections from pressure vessels have external threads to enable each component to be pressure tested with a threaded pipe cap during factory assembly. Cooler This vessel (also known as the evaporator) is located underneath the compressor. The cooler is maintained at lower temperature/pressure so that evaporating refrigerant can remove heat from water flowing through its internal tubes. Condenser The condenser operates at a higher temperature/pressure than the cooler and has water flowing through its internal tubes in order to remove heat from the refrigerant. Motor-Compressor This component maintains system temperature/pressure differences and moves the heat carrying refrigerant from the cooler to the condenser. Control Center The control center is the user interface for controlling the chiller. It regulates the chiller s capacity as required to maintain proper leaving chilled water temperature. The control center: registers cooler, condenser, and lubricating system pressures shows chiller operating condition and alarm shutdown conditions records the total chiller operating hours sequences chiller start, stop, and recycle under microprocessor control provides access to other CCN (Carrier Comfort Network) devices MODEL NUMBER NOMENCLATURE Fig. 1 19XR Identification 5

6 1 Oil Level Sight Glasses 2 Discharge Isolation Valve 3 Condenser Pumpout Connection 4 Condenser Safety Relief Valves 5 Three-Way Condenser Relief Valve 6 Hot Gas Bypass Line 7 Condenser Waterbox Nozzles 8 Cooler Waterbox Nozzles 9 Cooler Safety Relief Valve 10 Cooler Pumpout Connection 11 Control Panel 12 Guide Vane Actuator 13 Compressor/Transmission 14 Oil Pump 15 Power Panel 16 Oil Filter Isolation Valve 17 Oil Filter 18 Motor FRONT TOP VIEW 19 Oil Reclaim Filter 20 Float Chamber 21 Unit-Mounted Starter 22 Refrigerant Filter/Drier Isolation Valves 23 Sight Glass/Moisture Indicator 24 Filter/Drier 25 Cooler Liquid Line Isolation Valve 26 Refrigerant Charging Valve 27 Hot Gas Bypass Solenoid (Option) 28 Hot Gas Bypass Isolation Valve (Option) 29 Oil Reclaim Filter Isolation Valve 30 Waterbox Drains 31 Waterbox Vents BOTTOM REAR VIEW Fig.2 Typical 19XR Components 6

7 Factory-Mounted Starter (Optional) The starter allows for the proper start and disconnect of electrical energy for the compressor-motor, oil pump, oil heater, and control panels. Storage Vessel (Optional) There are 2 sizes of storage vessels available. The vessels have double relief valves, a magnetically coupled dial-type refrigerant level gage, a one-inch FPT drain valve, and a 1 2-in. male flare vapor connection for the pumpout unit. NOTE: If a storage vessel is not used at the jobsite, factoryinstalled isolation valves on the chiller may be used to isolate the chiller charge in either the cooler or condenser. An optional pumpout system is used to transfer refrigerant from vessel to vessel. REFRIGERATION CYCLE The compressor continuously draws refrigerant vapor from the cooler at a rate set by the amount of guide vane opening. As the compressor suction reduces the pressure in the cooler, the remaining refrigerant boils at a fairly low temperature (typically 38 to 42 F [3 to 6 C]). The energy required for boiling is obtained from the water flowing through the cooler tubes. With heat energy removed, the water becomes cold enough for use in an air conditioning circuit or process liquid cooling. After taking heat from the water, the refrigerant vapor is compressed. Compression adds still more heat energy, and the refrigerant is quite warm (typically 98 to 102 F [37 to 40 C]) when it is discharged from the compressor into the condenser. Relatively cool (typically 65 to 90 F [18 to 32 C]) water flowing into the condenser tubes removes heat from the refrigerant and the vapor condenses to liquid. The liquid refrigerant passes through orifices into the FLASC (Flash Subcooler) chamber (Fig. 3). Since the FLASC chamber is at a lower pressure, part of the liquid refrigerant flashes to vapor, thereby cooling the remaining liquid. The FLASC vapor is recondensed on the tubes which are cooled by entering condenser water. The liquid drains into a float chamber between the FLASC chamber and cooler. Here a float valve forms a liquid seal to keep FLASC chamber vapor from entering the cooler. When liquid refrigerant passes through the valve, some of it flashes to vapor in the reduced pressure on the cooler side. In flashing, it removes heat from the remaining liquid. The refrigerant is now at a temperature and pressure at which the cycle began. MOTOR/OIL REFRIGERATION COOLING CYCLE The motor and the lubricating oil are cooled by liquid refrigerant taken from the bottom of the condenser vessel (Fig. 3). Flow of refrigerant is maintained by the pressure differential that exists due to compressor operation. After the refrigerant flows past an isolation valve, an in-line Fig. 3 Refrigerant Motor Cooling and Oil Cooling Cycles 7

8 filter, and a sight glass/moisture indicator, the flow is split between motor cooling and oil cooling systems. Flow to the motor flows through an orifice and into the motor. Once past the orifice, the refrigerant is directed over the motor by a spray nozzle. The refrigerant collects in the bottom of the motor casing and then is drained back into the cooler through the motor refrigerant drain line. A back pressure valve or an orifice in this line maintains a higher pressure in the motor shell than in the cooler/oil sump. The motor is protected by a temperature sensor imbedded in the stator windings. An increase in motor winding temperature past the motor override set point will override the temperature capacity control to hold, and if the motor temperature rises 10 F (5.5 C) above this set point, will close the inlet guide vanes. If the temperature rises above the safety limit, the compressor will shut down. Refrigerant that flows to the oil cooling system is regulated by thermostatic expansion valves (TXVs). The TXVs regulate flow into the oil/refrigerant plate and frame-type heat exchanger. The expansion valve bulbs control oil temperature to the bearings. The refrigerant leaving the heat exchanger then returns to the cooler. LUBRICATION CYCLE Summary The oil pump, oil filter, and oil cooler make up a package located partially in the transmission casting of the compressor-motor assembly. The oil is pumped into a filter assembly to remove foreign particles and is then forced into an oil cooler heat exchanger where the oil is cooled to proper operational temperatures. After the oil cooler, part of the flow is directed to the gears and the high speed shaft bearings; the remaining flow is directed to the motor shaft bearings. Oil drains into the transmission oil sump to complete the cycle (Fig. 4). Details Oil is charged into the lubrication system through a hand valve. Two sight glasses in the oil reservoir permit oil level observation. Normal oil level is between the middle of the upper sight glass and the top of the lower sight glass when the compressor is shut down. The oil level should be visible in at least one of the 2 sight glasses during operation. Oil sump temperature is displayed on the LID default screen. Oil sump temperature ranges during compressor operation between 125 to 150 F (52 to 66 C). The oil pump suction is fed from the oil reservoir. An oil pressure relief valve maintains 18 to 25 psid (124 to 172 kpad) differential pressure in the system at the pump discharge. This differential pressure can be read directly from the Local Interface Device (LID) default screen. The oil pump discharges oil to the oil filter assembly. This filter can be closed to permit removal of the filter without draining the entire oil system (see Maintenance sections, pages 55 to 59, for details). The oil is then piped to the oil cooler. This heat exchanger uses refrigerant from the condenser as the coolant. The refrigerant cools the oil to a temperature between 120 and 140 F (49 to 60 C). As the oil leaves the oil cooler, it passes the oil pressure transducer and the thermal bulb for the refrigerant expansion valve on the oil cooler. The oil is then divided, with a portion flowing to the thrust bearing, forward pinion bearing, and gear spray. The balance then lubricates the motor shaft bearings and the rear pinion bearing. The oil temperature is measured as the oil leaves the thrust and forward journal bearings within the bearing housing. The oil then drains into the oil reservoir at the base of the compressor. The PIC (Product Integrated Control) measures the temperature of the oil in the sump and maintains the temperature during shutdown (see Oil Sump Temperature Control section, page 29). This temperature is read on the LID default screen. 8 During the chiller start-up, the PIC will energize the oil pump and provide 45 seconds of prelubrication to the bearings after pressure is verified before starting the compressor. During shutdown, the oil pump will run for 60 seconds to post-lubricate after the compressor shuts down. The oil pump can also be energized for testing purposes in the Control Test. Ramp loading can slow the rate of guide vane opening to minimize oil foaming at start-up. If the guide vanes open quickly, the sudden drop in suction pressure can cause any refrigerant in the oil to flash. The resulting oil foam cannot be pumped efficiently; therefore, oil pressure falls off and lubrication is poor. If oil pressure falls below 15 psid (103 kpad) differential, the PIC will shut down the compressor. If the controls are subject to a power failure that lasts more than 3 hours, the oil pump will be energized periodically when the power is restored. This helps to eliminate refrigerant that has migrated to the oil sump during the power failure. The controls will energize the pump for 60 seconds every 30 minutes until the chiller is started. Oil Reclaim System The oil reclaim system returns oil lost from the compressor housing back to the oil reservoir by recovering the oil from 2 areas on the chiller. The guide vane housing is the primary area of recovery. Oil is also recovered by skimming it from the operating refrigerant level in the cooler vessel. PRIMARY OIL RECOVERY MODE Oil is normally recovered through the guide vane housing on the chiller. This is possible because oil is normally entrained with the refrigerant in the chiller. As the compressor pulls the refrigerant up from the cooler into the guide vane housing to be compressed, the oil normally drops out at this point and falls to the bottom of the guide vane housing where it accumulates. Using discharge gas pressure to power an eductor, the oil is drawn from the housing and is discharged into the oil reservoir. SECONDARY OIL RECOVERY METHOD The secondary method of oil recovery is significant under light load conditions, when the refrigerant going up to the compressor suction does not have enough velocity to bring oil along with it. Under these conditions, oil normally collects in a greater concentration at the top level of the refrigerant in the cooler. This oil and refrigerant mixture is skimmed from the side of the cooler and is then drawn up to the guide vane housing. There is a filter in this line. Because the guide vane housing pressure is much lower than the cooler pressure, the refrigerant boils off, leaving the oil behind to be collected by the primary oil recovery method. STARTING EQUIPMENT The 19XR requires a motor starter to operate the centrifugal hermetic compressor motor, the oil pump, and various auxiliary equipment. The starter serves as the main field wiring interface for the contractor. See Carrier Specification Z-375 for specific starter requirements. All starters must meet these specifications in order to properly start and satisfy mechanical safety requirements. Starters may be supplied as separate, free-standing units or may be mounted directly on the chiller (unit mounted) for low-voltage units only. Inside the starter are 3 separate circuit breakers. Circuit breaker CB1 is the compressor motor circuit breaker. The disconnect switch on the starter front cover is connected to this breaker. Circuit breaker CB1 supplies power to the compressor motor.

9 REAR MOTOR BEARING FWD MOTOR BEARING LABYRINTH GAS LINE OIL SUPPLY TO FORWARD HIGH SPEED BEARING MOTOR COOLING LINE TXV BULB PRESSURE TRANSDUCER ISOLATION VALVE OIL COOLER OIL MOTOR OIL PUMP OIL HEATER EDUCTOR FILTER CHECK VALVE ISOLATION VALVE FILTER SIGHT GLASS ISOLATION VALVE Fig. 4 Lubrication System The main circuit breaker (CB1) on the front of the starter disconnects the main motor current only. Power is still energized for the other circuits. Two more circuit breakers inside the starter must be turned off to disconnect power to the oil pump, PIC controls, and oil heater. Circuit breaker CB2 supplies power to the control center, oil heater, and portions of the starter controls. Circuit breaker CB3 supplies power to oil pump. Both of these circuit breakers are wired in parallel with CB1 so that power is supplied to them if the CB1 disconnect is open. All starters must include a Carrier control module called the Starter Management Module (SMM). This module controls and monitors all aspects of the starter. See the Controls section on page 10 for additional SMM information. All starter replacement parts are supplied by the starter manufacturer. Unit-Mounted Solid-State Starter (Optional) The 19XR chiller may be equipped with a solid-state, reduced-voltage starter (Fig. 5 and 6). This starter provides on-off control of the compressor motor as its primary function. Using this type of starter reduces the peak starting torque, reduces the motor inrush current, and decreases mechanical shock. This is summed up by the phrase soft starting. The solid-state starter s manufacturer name will be located inside the starter access door. See Fig. 6. This type of starter operates by reducing the starting voltage. The starting torque of a motor at full voltage is typically 125% to 175% of the running torque. When the voltage and the current are reduced at start-up, the starting torque is reduced as well. The object is to reduce the starting voltage to just the voltage necessary to develop the torque required to get the motor moving. The voltage and current are then ramped up in a desired period of time. The voltage is reduced by using silicon controlled rectifiers (SCR). Once full voltage is reached, a bypass contactor is energized to bypass the SCRs. When voltage is supplied to the solid-state circuitry, the heat sinks within the starter are at line voltage. Do not touch the heat sinks while voltage is present or serious injury will result. There is a display on the front of the Benshaw, Inc., solidstate starters that is useful for troubleshooting and starter checkout. The display indicates: voltage to the SCRs SCR control voltage power indication proper phasing for rotation start circuit energized over-temperature ground fault current unbalance run state 9

10 G LL1 LL2 8A 8B 9A 9B 10A 10B 12A 12B 17A 43A T2 CB4 1 2 Unit-Mounted Wye-Delta Starter (Optional) The 19XR chiller may be equipped with a wye-delta starter mounted on the unit. This starter is intended for use with low-voltage motors (under 600 v). It reduces the starting current inrush by connecting each phase of the motor windings into a wye configuration. This occurs during the starting period when the motor is accelerating up to speed. After a time delay and once the motor is up to speed, the starter automatically connects the phase windings into a delta configuration LEGEND 1 Transformer 2 Circuit Breaker 4 (CB4): Power to SMM 3 Power Card 4 SMM 5 Circuit Breaker 3 (CB3): Oil Pump Power 6 Circuit Breaker 2 (CB2): Control and PIC Heater Power 7 Bypass Card (Bottom) 8 Power ON (LED1) 9 Microprocessor Fault (LED2) 10 Computer Card (Top-Mounted Board) 11 Reset Buttons Fig. 5 Solid-State Starter Box, Internal View Fig.6 Typical Starter External View (Solid-State Starter Shown) CB2 CB CONTROLS Definitions ANALOG SIGNAL An analog signal varies in proportion to the monitored source. It quantifies values between operating limits. (Example: A temperature sensor is an analog device because its resistance changes in proportion to the temperature, generating many values.) DIGITAL SIGNAL A digital (discrete) signal is a 2-position representation of the value of a monitored source. (Example: A switch is a digital device because it only indicates whether a value is above or below a set point or boundary by generating an on/off, high/low, or open/closed signal.) VOLATILE MEMORY Volatile memory is memory incapable of being sustained if power is lost and subsequently restored. The memory of the PSIO module is volatile. If the battery in a module is removed or damaged, all programming will be lost. General The 19XR hermetic centrifugal liquid chiller contains a microprocessor-based control center that monitors and controls all operations of the chiller. The microprocessor control system matches the cooling capacity of the chiller to the cooling load while providing state-of-the-art chiller protection. The system controls cooling load within the set point plus the deadband by sensing the leaving chilled water or brine temperature and regulating the inlet guide vane via a mechanically linked actuator motor. The guide vane is a variable flow prewhirl assembly that controls the refrigeration effect in the cooler by regulating the amount of refrigerant vapor flow into the compressor. An increase in guide vane opening increases capacity. A decrease in guide vane opening decreases capacity. Chiller protection is provided by the processor which monitors the digital and analog inputs (see Fig. 7) and executes capacity overrides or safety shutdowns, if required. PIC System Components The Product Integrated Control (PIC) is the control system on the chiller. See Table 1. The PIC controls the operation of the chiller by monitoring all operating conditions. The PIC can diagnose a problem and let the operator know what the problem is and what to check. It promptly positions the guide vanes to maintain leaving chilled water temperature. It can interface with auxiliary equipment such as pumps and cooling tower fans to turn them on only when required. It continually checks all safeties to prevent any unsafe operating condition. It also regulates the oil heater while the compressor is off and regulates the hot gas bypass valve, if installed. 10

11 The PIC can be interfaced with the Carrier Comfort Network (CCN) if desired. It can communicate with other PICequipped chillers and other CCN devices. The PIC consists of 3 modules housed inside the 3 major components. The component names and the control voltage contained in each component are listed below (also see Table 1): control center all extra low-voltage wiring (24 v or less) power panel 230 or 115 v control voltage (per job requirement) up to 600 v for oil pump power starter cabinet chiller power wiring (per job requirement) Table 1 Major PIC Components and Panel Locations* PIC COMPONENT PANEL LOCATION Processor Sensor Input/Output Module (PSIO) Control Center Starter Management Module (SMM) Starter Cabinet Local Interface Device (LID) Control Center 6-Pack Relay Board Control Center 8-Input Modules (Optional) Control Center Differential Oil Pressure/Power Supply Module Control Center Oil Heater Contactor (1C) Power Panel Oil Pump Contactor (2C) Power Panel Hot Gas Bypass Relay (3C) (Optional) Power Panel Control Transformers (T1, T2, T4) Power Panel Control and Oil Heater Voltage Selector (S1) Power Panel Temperature Sensors See Fig. 7 Pressure Transducers See Fig. 7 *See Fig. 5 and Fig PROCESSOR MODULE (PSIO) The PSIO is the brain of the PIC. This module contains all the operating software needed to control the chiller. The 19XR uses 4 pressure transducers and 8 thermistors to sense pressures and temperatures (Fig. 8 and 9). These are connected to the PSIO module. The PSIO also provides outputs to the guide vane actuator, oil pump, oil heater, hot gas bypass (optional), and alarm contact. The PSIO communicates with the LID, the SMM, and the optional 8-input modules for user interface and starter management. STARTER MANAGEMENT MODULE (SMM) This module is located within the starter cabinet. This module initiates PSIO commands for starter functions such as start/ stop of the compressor, start/stop of the condenser and chilled water pumps, start/stop of the tower fan, spare alarm contacts, and the shunt trip. The SMM monitors starter inputs such as flow switches, line voltage, remote start contact, spare safety, condenser high pressure, oil pump interlock, motor current signal, starter 1M and run contacts, and kw transducer input (optional). The SMM contains logic capable of safely shutting down the chiller if communications with the PSIO are lost. LOCAL INTERFACE DEVICE (LID) The LID is mounted to the control center (Fig. 10) and allows the operator to interface with the PSIO or other CCN devices. It is the input center for all local chiller set points, schedules, set-up functions, and options. The LID has a STOP button, an alarm light, 4 buttons for logic inputs, and a display. The function of the 4 buttons or softkeys are menu driven and are shown on the display directly above the key. 6-PACK RELAY BOARD This device is a cluster of 6 pilot relays located in the control center. It is energized by the PSIO for the oil pump, oil heater, alarm, optional hot gas bypass relay, and motor cooling solenoid. 8-INPUT MODULES One optional module is factory installed in the control center panel when ordered. There can be up to 2 of these modules per chiller with 8 spare inputs each. They are used whenever chilled water reset, demand reset, or reading a spare sensor is required. The sensors or 4 to 20 ma signals are field-installed. The spare temperature sensors must have the same temperature/resistance curve as the other temperature sensors on this unit. These sensors are 5,000 ohm at 75 F (25 C). OIL HEATER CONTACTOR (1C) This contactor is located in the power panel (Fig. 11) and operates the heater at either 115 or 230 v. It is controlled by the PIC to maintain oil temperature during chiller shutdown. OIL PUMP CONTACTOR (2C) This contactor is located in the power panel. It operates all 200 to 575-v oil pumps. The PIC energizes the contactor to turn on the oil pump as necessary. HOT GAS BYPASS CONTACTOR RELAY (3C) (Optional) This relay, located in the power panel, controls the opening of the hot gas bypass valve. The PIC energizes the relay during low load, high lift conditions. CONTROL TRANSFORMERS (T1, T2, T4) These transformers convert incoming control voltage to either 21 vac power for the PSIO module and options modules, or 24 vac power for 3 power panel contactor relays. They are located in the power panel. OIL DIFFERENTIAL PRESSURE/POWER SUPPLY MOD- ULE This module, which is located in the control center, provides 5 vdc power for the transducers and LID backlight. On open-drive chillers, this module outputs the difference between two pressure transducer input signals. The module subtracts oil supply pressure from transmission sump pressure and outputs the difference as an oil differential pressure signal to the PSIO. The PSIO converts this signal to differential oil pressure. To calibrate this reading, refer to the Troubleshooting, Checking Transistors section. CONTROLAND OIL HEATER VOLTAGE SELECTOR (S1) It is possible to use either 115 v or 230 v incoming control power in the power panel. The switch is set to the voltage used at the jobsite. 11

12 TOP VIEW VIEW A A(COMPRESSOR DETAIL) Fig. 7 19XR Controls and Sensor Locations Fig. 8 Control Sensors (Temperature) Fig. 9 Control Sensors (Pressure Transducer, Typical) 12

13 LID Operation and Menus (Fig ) LEGEND 1 LID 2 PSIO 3 8-Input Module (One of 2 Available) 4 5-Volt Transducer Power Supply 5 6-Pack Relay Board 6 Circuit Breakers (4) Fig. 10 Control Panel (Front View), with Options Module GENERAL The LID display will automatically revert to the default screen after 15 minutes if no softkey activity takes place and if the chiller is not in the Pumpdown mode (Fig. 12). When not in the default screen, the upper right-hand corner of the LID always displays the name of the screen that you have entered (Fig. 13). The LID may be configured in English or SI units, through the LID configuration screen. Local Operation By pressing the LOCAL softkey, the PIC is now in the LOCAL operation mode and the control will accept modification to programming from the LID only. The PIC will use the Local Time Schedule to determine chiller start and stop times. CCN Operation By pressing the CCN softkey, the PIC is now in the CCN operation mode, and the control will accept modifications from any CCN interface or module (with the proper authority), as well as the LID. The PIC will use the CCN time schedule to determine start and stop times. ALARMS AND ALERTS Alarm (*) and alert (!) status are indicated on the Status tables on the far right field of the LID display screen. An alarm (*) will shut down the compressor. An alert (!) notifies the operator that an unusual condition has occurred. The chiller will continue to operate when an alert is shown. LEGEND 1 T2 24 vac Power Transformer for Hot Gas Bypass Relay, Oil Pump Relay, Oil Heater Relay, Motor Cooling Solenoid, Oil Reclaim Solenoid 2 Oil Pressure Switch 3 T4 24 vac, Optional 8-Input Module Transformer 4 T1 24 vac, Control Center Transformer 5 3C Hot Gas Bypass Relay Location 6 Oil Pump Terminal Block 7 Factory Terminal Connections Fig. 11 Power Panel with Options 13

14 Press the MENU softkey to select from the 4 options. To view or change parameters within any menu structure, use the SELECT softkey to choose the desired table or item. The soft key modification choices displayed will depend on whether the selected item is a discrete point, analog point, or an override point. At this point, press the softkey that corresponds to your configuration selection or press the QUIT softkey. If the QUIT softkey is depressed, the configuration will not be modified. Refer to the following Menu Structure section. MENU STRUCTURE To perform any of the operations described below, the PIC must be powered up and have successfully completed its self test. The self-test takes place automatically, after power-up. Fig. 12 LID Default Screen Press QUIT to leave the selected decision or field without saving any changes. Press ENTER to leave the selected decision or field and save changes. Press NEXT to scroll the cursor bar down in order to highlight a point or to view more points below the current screen. Fig. 13 LID Service Screen Alarms are indicated when the control center alarm light (!) flashes. The primary alarm message is displayed on the default screen and an additional, secondary, message and troubleshooting information are sent to the Alarm History table. When an alarm is detected, the LID default screen will freeze (stop updating) at the time of alarm. The freeze enables the operator to view the chiller conditions at the time of alarm. The Status tables will show the updated information. Once all alarms have been cleared (by pressing the RESET softkey), the default LID screen will return to normal operation. LID DEFAULT SCREEN MENU ITEMS To perform any of the operations described below, the PIC must be powered up and have successfully completed its self test. The self test takes place automatically, after power-up. The Default screen menu selection offers 4 options (Status, Schedule, Setpoint, and Service). The Status menu allows for viewing and limited calibration/modification of control points and sensors, relays and contacts, and the options board. The Schedule menu allows for the viewing and modification of the Local Control, CCN Control, and Ice Build time schedules. Under the Setpoint menu, numerous set points including Base Demand Limit, LCW, ECW, and Ice Build can be adjusted. The Service menu can be used to revise alarm history, control test, control algorithm status, equipment configurations, equipment service, time and date, attach to network, log out of device, controller identification, and LID configurations. Figures 15 and 16 provide additional information on the menu structure. 14 Press PREVIOUS to scroll the cursor bar up in order to highlight a point or to view points above the current screen. Press SELECT to view the next screen level (highlighted with the cursor bar), or to override (if allowable) the highlighted point value. Press EXIT to return to the previous screen level. Press INCREASE or DECREASE to change the highlighted point value.

15 TO VIEW POINT STATUS (Fig. 14) Point Status is the actual value of all of the temperatures, pressures, relays, and actuators sensed and controlled by the PIC. 1. On the Menu screen, press STATUS to view the list of Point Status tables. OVERRIDE OPERATIONS To Override a Value or Status 1. On the Point Status table press NEXT or PREVIOUS to highlight the desired point. 2. Press SELECT to select the highlighted point. Then: 2. Press NEXT or PREVIOUS to highlight the desired status table. The list of tables is: Status01 Status of control points and sensors Status02 Status of relays and contacts Status03 Status of both optional 8-input modules and sensors For Discrete Points Press START or STOP to select the desired state. 3. Press SELECT to view the desired Point Status table desired. For Analog Points Press INCREASE or DECREASE to select the desired value. 3. Press ENTER to register new value. 4. On the Point Status table press NEXT or PREVIOUS until desired point is displayed on the screen. NOTE: When overriding or changing metric values, it is necessary to hold down the softkey for a few seconds in order to see a value change, especially on kilopascal values. To Remove an Override 1. On the Point Status table press NEXT or PREVIOUS to highlight the desired point. 2. Press SELECT to access the highlighted point. 3. Press RELEASE to remove the override and return the point to the PIC s automatic control. Fig. 14 Example of Point Status Screen (Status01) Override Indication An override value is indicated by SUPVSR, SERVC, or BEST flashing next to the point value on the Status table. 15

16 16 Fig XR Menu Structure

17 17 Fig XR Service Menu Structure

18 TIME SCHEDULE OPERATION (Fig. 17) 1. On the Menu screen, press SCHEDULE. b. Press ENABLE to select days in the day-of-week fields. Press DISABLE to eliminate days from the period. 2. Press NEXT or PREVIOUS to highlight the desired schedule. OCCPC01S LOCAL Time Schedule OCCPC02S ICE BUILD Time Schedule OCCPC03-99S CCN Time Schedule (Actual number is defined in Config table.) 7. Press ENTER to register the values and to move horizontally (left to right) within a period. 8. Press EXIT to leave the period or override. 3. Press SELECT to access and view the time schedule. 4. Press NEXT or PREVIOUS to highlight the desired period or override that you wish to change. 9. Either return to Step 4 to select another period or override, or press EXIT again to leave the current time schedule screen and save the changes. 5. Press SELECT to access the highlighted period or override. 10. Holiday Designation (HOLIDEF table) may be found in the Service Operation section, page 35. You must assign the month, day, and duration for the holiday. The Broadcast function in the Brodefs table also must be enabled for holiday periods to function. 6. a. Press INCREASE or DECREASE to change the time values. Override values are in one-hour increments, up to 4 hours. TO VIEW AND CHANGE SET POINTS (Fig. 18) 1. To view the Set Point table, at the Menu screen press SETPOINT. Fig. 17 Example of Time Schedule Operation Screen Fig. 18 Example of Set Point Screen 18

19 2. There are 4 set points on this screen: Base Demand Limit; LCW Set Point (leaving chilled water set point); ECW Set Point (entering chilled water set point); and ICE BUILD set point. Only one of the chilled water set points can be active at one time, and the type of set point is activated in the Service menu. ICE BUILD is also activated and configured in the Service menu. 3. Press NEXT or PREVIOUS to highlight the desired set point entry. 5. Press INCREASE or DECREASE to change the selected set point value. 6. Press ENTER to save the changes and return to the previous screen. 4. Press SELECT to modify the highlighted set point. SERVICE OPERATION To view the menu-driven programs available for Service Operation, see Service Operation section, page 35. For examples of LID display screens, see Table 2. Table 2 LID Screens NOTES: 1. Only 12 lines of information appear on the LID screen at any given time. Press NEXT or PREVIOUS to highlight a point or to view points below or above the current screen. 2. The LID may be configured in English or SI units, as required, using the LID configuration screen. 3. The items listed in the Reference Point Names column do not appear on the LID display screen. They are data or variable names used for CCN operations only. They are listed here as a convenience to the operator if it is necessary to cross reference CCN documentation or use CCN programs. EXAMPLE 1 STATUS01 DISPLAY SCREEN To access this display from the LID default screen: 1. Press MENU. 2. Press STATUS (STATUS01 will be highlighted). 3. Press SELECT. DESCRIPTION RANGE UNITS REFERENCE POINT NAME (ALARM HISTORY) Control Mode Reset, Off, Local, CCN MODE Run Status Timeout, Recycle, Startup, STATUS Ramping, Running, Demand, Override, Shutdown, Abnormal, Pumpdown Occupied? No/Yes OCC Alarm State Normal/Alarm ALM *Chiller Start/Stop Stop/Start CHIL S S Base Demand Limit % DLM *Active Demand Limit % DEM LIM Compressor Motor Load % CA L Current % CA P **Amps AMPS CA A *Target Guide Vane Pos % GV TRG Actual Guide Vane Pos % GV ACT Water/Brine: Setpoint ( ) DEG F (DEG C) SP *Control Point ( ) DEG F (DEG C) LCW STPT Entering Chilled Water ( ) DEG F (DEG C) ECW Leaving Chilled Water ( ) DEG F (DEG C) LCW Entering Condenser Water ( ) DEG F (DEG C) ECDW Leaving Condenser Water ( ) DEG F (DEG C) LCDW Evaporator Refrig Temp ( ) DEG F (DEG C) ERT **Evaporator Pressure ( ) PSI (kpa) ERP Condenser Refrig Temp ( ) DEG F (DEG C) CRT **Condenser Pressure ( ) PSI (kpa) CRP Discharge Temperature ( ) DEG F (DEG C) CMPD Bearing Temperature ( ) DEG F (DEG C) MTRB Motor Winding Temp ( ) DEG F (DEG C) MTRW Oil Sump Temperature ( ) DEG F (DEG C) OILT **Oil Pressure ( ) PSID (kpad) OILPD Line Voltage: **Percent % V P Actual VOLTS V A *Remote Contacts Input Off/On REMCON Total Compressor Starts c starts Starts in 12 Hours 0-8 STARTS Compressor Ontime HOURS c hrs *Service Ontime HOURS S HRS *Compressor Motor kw kw CKW NOTE: All values are variables available for read operation to a CCN. Descriptions shown with (*) support write operations for BEST programming language, data-transfer, and overriding. Descriptions shown with (**) may be calibrated from the LID. 19